Plastic container including plastic hinge assembly

ABSTRACT

A container that is preferably formed entirely of molded plastic materials includes a container body and a lid secured to the container body via a hinge assembly. The hinge assembly includes a hinge pin having a head and a shaft, where the hinge pin head has a maximum diameter substantially matching a maximum diameter of the shaft. With this construction, the container assembly can be easily and cost-effectively automated.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 60/519,253, filed Nov. 13, 2003, the entire contentof which is herein incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

(Not Applicable)

BACKGROUND OF THE INVENTION

The present invention relates to a plastic container and, moreparticularly, to a plastic container including a hinge assembly with asubstantially straight plastic hinge pin suitable for automatedassembly.

Attempts have been made to automate the assembly of plastic containersincluding lids and the like, but problems have arisen that preventcost-efficient automation. For example, hinge pins are typically formedof aluminum or other metal material for its strength characteristics toprevent the hinge from being broken into. In order to secure such pinsin place, a bend is typically formed at an end thereof after insertion.It is considerably expensive if not impossible to automate the processof bending the hinge pins after installation into the hinge. Using astraight hinge pin could solve the problem, but then it becomesdifficult to prevent the pin from working its way out with extended useor possibly being removed in an attempt to break into the container.

Plastic hinge pins have been proposed, but it becomes difficult tosecure the pin in the hinge. Moreover, plastic hinge pins may be subjectto tampering, thereby making it easier to break into a container. Insome cases the lids are attached using a C-clip connection by snappingthe lid onto a molded pin on the container. This type of connection doesnot provide an adequate security level since the lid can be removedeasily, even if a wire tie is used. Also, the lid can become separatedfrom the container during transport or use.

BRIEF SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide a containerincluding a hinge assembly using a plastic hinge pin that is suitablefor automation while overcoming the drawbacks associated with priorattempts. The proposed design uses both a strong and secure snap fit forthe hinge pin, which provides an initial engagement between the lid andthe container body and a relatively short plastic hinge pin that securesthe lid to the container. The initial attachment of the lid to thecontainer can be automated using a clamping device, and the installationof the substantially straight hinge pin can also be automated using anail gun type or magazine type assembly device or the like. Both theclamping device and the pin insertion device can be incorporated intoone assembly machine.

In an exemplary embodiment of the invention, a container includes acontainer body including side walls, and at least one lid pivotablyattached to a corresponding at least one of the side walls via a hingeassembly. The hinge assembly includes a hinge pin having a head and ashaft, wherein the hinge pin is formed of a plastic material, andwherein the hinge pin head has a maximum diameter substantially matchinga maximum diameter of the shaft. The container body, the at least onelid, and the hinge assembly are preferably formed of a plastic material,for example, of molded plastic materials. In one arrangement, the hingepin is constructed to be tamper-evident. For example, the hinge pin maybe formed of a plastic material that is differently colored from theplastic material of the hinge assembly.

The at least one side wall may include a first hinge pin receivingchannel, wherein the at least one lid may include a second hinge pinreceiving channel. The first and second hinge pin receiving channels arealigned to receive the hinge pin when the lid is attached to the sidewall. In this context, the at least one side wall may include a pair ofspaced first hinge pin receiving channels, with the second hinge pinreceiving channel being fit between the first hinge pin receivingchannels when the lid is attached to the side wall.

In a preferred arrangement, the hinge assembly receives the hinge pin ina snap fit. In this context, the hinge pin shaft may have a reduceddiameter adjacent the hinge pin head. Additionally, the hinge pin headpreferably tapers inward toward a head tip.

In another exemplary embodiment of the invention, a container formedentirely of molded plastic materials includes a container body and a lidsecured to the container body via a hinge assembly, wherein the hingeassembly includes a hinge pin having a head and a shaft, and wherein thehinge pin head has a maximum diameter substantially matching a maximumdiameter of the shaft. The container may be assembled in an automatedtwo-step process, where the steps include (1) using a clamping devicefor an initial attachment of the lid to the container body, and (2)inserting the hinge pin into the hinge assembly.

In yet another exemplary embodiment of the invention, a plastic hingeassembly is provided for pivotably attaching a first member to a secondmember. The hinge assembly includes a first hinge pin receiving channelon the first member, and a second hinge pin receiving channel on thesecond member. The first and second hinge pin receiving channels arealigned when the first member is attached to the second member. A hingepin having a head and a shaft is insertable through the aligned firstand second hinge pin receiving channels. The hinge pin head has amaximum diameter substantially matching a maximum diameter of the shaft.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects and advantages of the present invention will bedescribed in detail with reference to the accompanying drawings, inwhich:

FIG. 1 is a perspective view of an exemplary container of the presentinvention;

FIG. 2 is an assembly drawing illustrating the hinge assembly of thepresent invention; and

FIG. 2A is a close-up view of the hinge pin shaft and head.

DETAILED DESCRIPTION OF THE INVENTION

The container illustrated in FIG. 1 is exemplary as many other containerconfigurations may benefit from the subject matter of the presentinvention. Additionally, the hinge assembly and the manner of securingthe lid(s) to the container body is also exemplary. The invention is notnecessarily meant to be limited to the container and hinge assemblyshown in the drawings.

The container 10 in FIG. 1 includes a main body portion 12 formed by abottom, side walls and end walls. A pair of complementary shaped lidmembers 14 are secured via a hinge assembly 16 to an uppermost surfaceof the side walls as shown. With the exemplary container shown in FIG.1, in a closed position, the lid members 14 cooperate to close thecontainer 10. Of course, the container 12 may alternatively include asingle lid member or even additional lid members.

With continued reference to FIG. 1 and with reference to FIG. 2, thehinge assembly 16 is preferably formed entirely of molded plasticmaterials including a plastic hinge pin 18. Each lid member 14 includesa series of hinge members including a support portion 20 moldedintegrally with the lid 14 and a pair of generally cylindrical pegs 22extending from the support portion 20, the pegs and support portionbeing constructed generally in a “rolling pin” shape. The supportportion 20 may alternatively have a cylindrical, square, rectangular orother shaped cross section depending on a desired appearance for theassembled container.

Corresponding hinge receiving sections 24 of the hinge assembly 16 areformed integral with the container side walls. The hinge receivingsections 24 define a plurality of snap receptacles 26 that receive thecylindrical pegs 22 of the hinge members on the lid 14 in a snap fit.

The lid members 14 also include a hinge pin receiving channel 28 atoutside ends of the lid members 14. Each hinge pin receiving channel 28is disposed adjacent at least one corresponding channel 30 formed on thetop portion of the container side walls. In a preferred arrangementshown in FIG. 2, a pair of hinge pin receiving channels 30 are providedon the container side wall in a spaced configuration such that the pinreceiving channel 28 on the lid 14 is fit between the pair ofcorresponding channels 30 on the container body 12.

When the lid hinge members 20, 22 are snapped into engagement with thehinge receiving sections 24 on the container side walls, the hinge pinreceiving channel 28 of the lid is aligned with the correspondingchannels 30 on the container side walls, thereby defining a hinge pinreceiving chamber. The plastic hinge pin 18 is inserted into each hingepin receiving chamber to secure the lids 14 in place.

To facilitate automation of the assembly process, the hinge pin head 18Ahas a maximum diameter substantially matching a maximum diameter of thehinge pin shaft 18B (see FIG. 2A) The hinge pin shaft 18B has a reduceddiameter adjacent the hinge pin head 18A. With this construction, thehinge assembly 16 receives the hinge pin 18 in a snap fit. That is, thehinge pin receiving channel 30 on the container side wall includes aplastic opening having a width generally corresponding to the reduceddiameter section of the hinge pin shaft 18B. The hinge pin head 18Atapers slightly inward toward the head tip as shown in FIG. 2A, and asthe hinge pin 18 is pushed into the opening of the hinge pin receivingchannel 30, the hinge pin head 18A deflects the plastic opening, and thehinge pin receiving channel 30 receives the hinge pin 18 in a snapengagement surrounding the reduced diameter area of the hinge pin shaft18B.

When the lidded container is sealed using a wire tie or othertamper-evident seal, the lid 14 cannot be removed from the containerwithout breaking the plastic hinge pin 18 or the lid 14 itself. Thedesign of the hinge assembly 16 makes it very difficult to remove thehinge pin 18, and subsequently the lid 14, in a short time period andwithout leaving any evidence. Additionally, in one arrangement, thehinge pin 18 can be manufactured in a specific color, different from thecolor of the container and lid, thereby making it easy to see if the pin18 has been removed. Moreover, the unique design and size of the hingepin 18 make it difficult for anyone tampering with the lid attachment toreplace a damaged pin, since the pin 18 is not readily available in themarketplace.

As noted, the assembled product is preferably made of 100% plasticmaterial, thereby making it simple and cost-effective to recycle theproduct. Manufacture and assembly of the container are also facilitated.Assembly can be automated using a two-step process, wherein the initialattachment of the lid 14 to the container body 12 can be automated usinga clamping device, and the installation of the substantially straighthinge pin 18 can be automated using a nail gun or magazine type assemblydevice or the like. Both the clamping device and the pin insertiondevice can be incorporated into a single assembly machine.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims.

1. A container comprising: a container body including side walls; and atleast one lid pivotably attached to a corresponding at least one of theside walls via a hinge assembly including a hinge pin having a head anda shaft, wherein the hinge pin is formed of a plastic material, andwherein the hinge pin head has a maximum diameter substantially matchinga maximum diameter of the shaft.
 2. A container according to claim 1,wherein the container body, the at least one lid, and the hinge assemblyare formed of a plastic material.
 3. A container according to claim 2,wherein the container body, the at least one lid, and the hinge assemblyare formed of molded plastic materials.
 4. A container according toclaim 2, wherein the hinge pin is constructed to be tamper-evident.
 5. Acontainer according to claim 2, wherein the hinge pin is formed of aplastic material that is differently colored from the plastic materialof the hinge assembly.
 6. A container according to claim 1, wherein theat least one side wall comprises a first hinge pin receiving channel,and wherein the at least one lid comprises a second hinge pin receivingchannel, the first and second hinge pin receiving channels being alignedto receive the hinge pin when the lid is attached to the side wall.
 7. Acontainer according to claim 6, wherein the at least one side wallcomprises a pair of spaced first hinge pin receiving channels, thesecond hinge pin receiving channel being fit between the first hinge pinreceiving channels when the lid is attached to the side wall.
 8. Acontainer according to claim 1, wherein the hinge assembly receives thehinge pin in a snap fit.
 9. A container according to claim 8, whereinthe hinge pin shaft has a reduced diameter adjacent the hinge pin head.10. A container according to claim 1, wherein the hinge pin head tapersinward toward a head tip.
 11. A container formed entirely of moldedplastic materials, the container comprising a container body and a lidsecured to the container body via a hinge assembly, wherein the hingeassembly includes a hinge pin having a head and a shaft, and wherein thehinge pin head has a maximum diameter substantially matching a maximumdiameter of the shaft.
 12. A container according to claim 11, whereinthe hinge pin is constructed to be tamper-evident.
 13. A containeraccording to claim 11, wherein the hinge pin is formed of a plasticmaterial that is differently colored from the plastic material of thehinge assembly.
 14. A container according to claim 11, wherein the hingeassembly receives the hinge pin in a snap fit.
 15. A container accordingto claim 14, wherein the hinge pin shaft has a reduced diameter adjacentthe hinge pin head.
 16. A container according to claim 10, wherein thehinge pin head tapers inward toward a head tip.
 17. A method ofassembling the container of claim 11 in an automated two-step process,the steps comprising (1) using a clamping device for an initialattachment of the lid to the container body, and (2) inserting the hingepin into the hinge assembly.
 18. A plastic hinge assembly for pivotablyattaching a first member to a second member, the hinge assemblycomprising: a first hinge pin receiving channel on the first member; asecond hinge pin receiving channel on the second member, wherein thefirst and second hinge pin receiving channels are aligned when the firstmember is attached to the second member; and a hinge pin having a headand a shaft is insertable through the aligned first and second hinge pinreceiving channels, wherein the head has a maximum diametersubstantially matching a maximum diameter of the shaft.
 19. A plastichinge assembly according to claim 18, comprising a pair of spaced firsthinge pin receiving channels, the second hinge pin receiving channelbeing fit between the first hinge pin receiving channels when the firstmember is attached to the second member.
 20. A plastic hinge assemblyaccording to claim 18, wherein the hinge assembly receives the hinge pinin a snap fit.
 21. A plastic hinge assembly according to claim 20,wherein the hinge pin shaft has a reduced diameter adjacent the hingepin head.
 22. A plastic hinge assembly according to claim 18, whereinthe hinge pin head tapers inward toward a head tip.